Machine for producing laundry products

ABSTRACT

AN IMPROVED MACHINE AND METHOD FOR PRODUCING A LAUNDRY PRODUCT COMPRISING GENERALLY SPHERICAL BEADS FORMED FROM PARTICLES OF SOAP, SYNTHETIC DETERGENT, OR THE LIKE. IN THE MACHINE AND METHOD OF THIS INVENTION, THE PARTICLES ARE FORMED INTO AN ANNULAR FLUIDIZED BED OF PARTICLES AND GAS IN A ROTATABLE CHAMBER AS A RESULT OF RELATIVELY HIGH SPEED ROTATION OF THE CHAMBER AND CONTINUOUS INTRODUCTION OF GAS INTO THE ROTATING CHAMBER. PERIODICALLY THE PARTICLES ARE TUMBLED IN THE CHAMBER BY ABRUPTLY REDUCING THE ROTATIONAL SPEED OF THE CHAMBER. THE PARTICLES MAY BE TREATED IN THE CHAMBER BY THE INTRODUCTION OF FLUIDS ONTO THE PARTICLES IN THE ROTATING CHAMBER. THE MACHINE OF THE PRESENT INVENTION ALSO INCLUDES NOVEL MEANS FOR INTRODUCING THE PARTICLES INTO THE ROTATING CHAMBER, FOR REMOVING THE BEADS FROM THE ROTATING CHAMBER, FOR INTRODUCING GAS UNDER PRESSURE INTO THE ROTATING CHAMBER TO FLUIDIZE THE PARTICLES IN THE ANNULAR BED, AND FOR RECIRCULATING THE GAS EXHAUSTED FROM THE CHAMBER BACK INTO THE ROTATING CHAMBER. THE GENERALLY SPHERICAL BEADS OF SOAP, SYNTHETIC DETERGENT OR THE LIKE PRODUCED BY THE MACHINE AND METHOD OF THIS INVENTION ARE RELATIVELY DENSE, HAVE A RELATIVELY LOW MOISTING CONTENT AND MAY INCLUDE ONE OR MORE OUTER LAYERS OR COATINGS OF SOLIDIFIED TREATING FLUID, WITH EACH BEAD CONTAINING SUBSTANTIALLY THE SAME MATERIALS AND PROPORTION OF MATERIALS AS ARE IN THE OTHER BEADS.

June 29, 1971 E. MARSHALL MACHINE FOR PRODUCING LAUNDRY PRODUCTS 3 Sheets-Sheet l Filed Nov.

INVbN? 0R. DONALD E. MAEJMM June 29, 1971 D. E. MARSHALL 3,588,950

MACHINE FOR PRODUCING LAUNDRY PRODUCTS Filed Nov. 5, 1968 5 Sheets-Sheet 2 INVIN'I (m Damza Z. MAESHAlt June 29, 1971 0. E. MARSHALL 3,588,959

MACHINE FOR PRODUCING LAUNDRY PRODUCTS Filed Nov. 5. 1968 3 Sheets-Sheet Z United States Patent 3,588,950 MACHINE FOR PRODUCING LAUNDRY PRODUCTS Donald E. Marshall, 4904 Sunnyside Road, Edina, Minn. 55424 Filed Nov. 5, 1968, Ser. No. 773,585 Int. Cl. B22d 13/00 U.S. Cl. 182.5 29 Claims ABSTRACT OF THE DISCLOSURE An improved machine and method for producing a laundry product comprising generally spherical beads formed from particles of soap, synthetic detergent, or the like. In the machine and method of this invention, the particles are formed into an annular fluidized bed of particles and gas in a rotatable chamber as a result of relatively high speed rotation of the chamber and continuous introduction of gas into the rotating chamber. Periodically the particles are tumbled in the chamber by abruptly reducing the rotational speed of the chamber. The particles may be treated in the chamber by the introduction of fluids onto the particles in the rotating chamber. The machine of the present invention also includes novel means for introducing the particles into the rotating chamber, for removing the beads from the rotating chamber, for introducing gas under pressure into the rotating chamber to fiuidize the particles in the annular bed, and for recirculating the gas exhausted from the chamber back into the rotating chamber.

The generally spherical beads of soap, synthetic detergent or the like produced by the machine and method of this invention are relatively dense, have a relatively low moisture content and may include one or more outer layers or coatings of solidified treating fluid, with each bead containing substantially the same materials and proportion of materials as are in the other beads.

BACKGROUND OF THE INVENTION This invention relates to an improved machine and method for producing laundry products, and more particularly, to an improved machine and method for producing a novel dense, low moisture, generally spherical bead of soap, detergent or the like. The beads of the present invention may consist of nucleus of one type of laundry material and an outer continuous layer(s) of other laundry materials.

In the past, conventional laundry products, such as the particles of soap and synthetic detergents, have been generally made in conventional spray towers. These particles have had a generally irregular shape, have been porous and have had a moisture content of above ten percent by weight. Also in the past, spherical bead products have been shaped in conventional pill rolling machines in which the products to be shaped are placed in the large drums or chambers and rotated therein at a relatively low rotational speed so that the products or particles are continuously tumbled in the drum.

In contrast, the machines of the present invention include a rotatable, horizontally disposed chamber in which the particles to be shaped and/ or treated are rotated at a relatively high speed so that the particles form an annular bed or layer about the central longitudinal axis of the chamber and adjacent to the side wall of the chamber. Gas under pressure is continuously introduced into the rotating chamber so as to fluidize the annular bed of particles so that the particles in the bed are in a constant state of agitated motion whereby the particles are continuously contacting or striking adjacent particles and the walls of the chamber. Periodically the rotational speed of the chamber is reduced from said relatively high speed to an intermediate speed. The intermediate speed is se- 3,588,950 Patented June 29, 1971 lected so that the centrifugal force acting on the particles is less than the gravitational force acting thereon whereby the particles in the upper segment of the chamber fall away from the side wall of the chamber and are cast down upon the lower segment of the chamber and the particles therein. This tumbling compacts and hardens the surface of the particles and assists in shaping the particles.

The machines of the present invention have a unique fan-plenum chamber assembly which includes a plurality of fan blades mounted on each of the end walls of the chamber at points equi-spaced from each other and spaced radially inwardly from the side Wall of the chamber. A plurality of holes are drilled in the end walls of the chamber adjacent to, but spaced radially inward from the side wall thereof. A plenum chamber extends radially outwardly from each of the fan blades to the peripheral edge of the chamber so that the radial outer ends of the plenum chamber overlies one or more of the holes and connects the holes with the base of the fan blades. The longitudinal axes of each of the fan blades and the plenum chambers is disposed at an acute angle with a radius of the rotating chamber, with the fan blade being positioned ahead, relative to the direction of rotation of the chamber, of the respective holes with which the fan blade is connected by the plenum chamber, whereby the plenum chambers assist in the movement of gas radially through the plenum chamber and through the holes.

The rotating chamber is positioned in a shroud and gas is introducd into the shroud from a motor driven blower. The gas in the shroud may be heated prior to its introduction into the rotating chamber and after the gas passes through the annular bed of fluidized particles and gas in the chamber, the gas is exhausted from the chamber through an aperture located adjacent the central longitudinal axis of the chamber. A portion of this exhaust gas may be recirculated back into the interior of the shroud after passing through a filter. In another embodiment of the machine of the present invention gas is introduced into the rotating chamber by means of a central manifold mounted on one of the end walls of the chamber and a plurality of radial and transverse tubes interconnecting the manifold with the chamber. The manifold is connected with a source of gas under pressure such as a rotary compressor.

The machines of the present invention also include novel means for introducing particles into the rotating chamber, for removing beads from the rotating chamber and for introducing liquid for treating the particles onto the particles in the rotating chamber.

Therefore, it is the primary object of the present invention to provide an improved machine and method for producing a laundry product comprising dense, generally spherical beads which may have a nucleus of one material and an outer layer of other materials.

Another object of the present invention is to provide an improved machine for shaping and treating particles of soap, synthetic detergent and the like wherein the particles to be shaped and treated are positioned in a rotatable chamber which is rotated at a relatively high speed so that the particles form and maintain a generally annular bed about the central axis of the chamber; wherein gas is continuously introduced under pressure into the annular bed so that the particles therein are fluidized, and wherein periodically the fluidized particles in the bed are tumbled in the rotating chamber. A related object of the present invention is to provide an improved machine of the type described wherein the speed of the rotating chamber is periodically abruptly reduced from the relatively high speed to an intermediate speed whereby a portion of the fluidized particles fall away from the upper segment of the rotating chamber and are cast down upon the lower segment of the rotating chamber. A still further related object of 3 the present invention is to provide an improved machine of the type described wherein the rotational speed of the chamber is quickly returned to the relatively high speed after a reduction in rotational speed so that the annular bed of fluidized particles and gas is again formed.

Still another object of the present invention is to provide an improved method of shaping and treating particles of soap, synthetic detergent and the like wherein the particles are rotated in a chamber at a relatively high speed so that the particles form and maintain a generally annular bed about the rotational axis of the chamber; wherein the particles are fluidized in the annular bed by the continuous introduction of the gas under pressure into the bed; and wherein periodically the fluidized particles are tumbled in the rotating chamber. A related object of the present invention is to provide an improved method of the type described wherein the particles are tumbled in the chamber by reducing the rotational speed of the chamber from the relatively high speed to an intermediate speed whereby a large portion of the fluidized particles fall away from the side wall of the chamber and are cast down on a lower segment of the rotating chamber; and wherein the annular, fluidized bed of particles and gas is reformed again by quickly returning the chamber to the relatively high speed.

Another object of the present invention is to provide an improved laundry product of the type described which comprises a plurality of substantially spherical beads having a density greater than fifty pounds per cubic foot and a moisture content of less than five percent by weight;

wherein each of the beads consists of an irregularly shaped nucleus and at least one continuous layer formed about the nucleus; and wherein each of the beads contains substantially the same materials and proportion of materials as are in the other beads so that all beads are substantially chemically identical.

These and other objects of the present invention will become apparent from the accompanying specification, claims and drawings.

DESCRIPTION OF THE DRAWINGS FIG. 1 is a vertical cross-sectional view of an improved machine embodying the principles of the present invention.

FIG. 2 is a partial vertical cross-sectional view taken along lines 22 in FIG. 1.

FIG. 3 is a perspective view of a fan and plenum chamber utilized in the machine shown in FIG. 1.

FIG. 4 is a vertical cross-sectional view taken along lines 4-4 in FIG. 1 and showing the annular layer of fluidized particles and gas formed in the rotating chamber.

FIG. 5 is a vertical cross-sectional view taken along lines 4-4 in FIG. 1 and showing the particles in the rotating chamber being tumbled during a period in which the chamber is rotating at an intermediate speed.

FIG. 6 is a vertical cross-sectional view taken along lines 4-4 in FIG. 1 and showing the trough in position for removing beads from the rotating chamber.

FIG. 7 is a partial, vertical cross-sectional view of an improved machine, embodying the principles of the present invention, which has a modified means for introducing gas under pressure into the rotating chamber.

FIG. 8 is a partial, vertical cross-sectional view taken along lines 88 in FIG. 7.

DESCRIPTION OF THE PREFERRED EMBODIMENT An improved machine embodying the principles of the present invention is shown generally at 11. The machine 11 includes a sheet metal shroud 12 which is secured to the floor 13 by a plurality of conventional fasteners, not shown. The shroud 12 is constructed so as to prevent the leakage of gas from the interior thereof during the operation of the machine and includes a front wall 14, a top wall 15, a rear wall 16 and a bottom wall 17 which slopes forwardly, or to the left as shown in FIG. 1. A hinged clean-out door 18 is located in the front wall 14, near the floor, and permits access to the interior of the shroud for the purpose of removing dirt, dust and the like therefrom.

The central portion 19 of the front wall 14 of the shroud 12 is flared outwardly, or in other words, projects to the left as shown in FIG. 1. A central aperture 21 is formed in the portion 19, and a tube 22 is secured within the aperture 21 so that approximately one-third of the tube projects forwardly from the front wall 14, and so that the right end 23 of the tube 22 extends within the shroud. A conventional, annular gas filter 24 is positioned within the tube 22 and is designed to permit gas to pass radially, with respect to the central longitudinal axis of the tube, therethrough. The righthand portion of the tube 22, i.e., the two-thirds portion thereof positioned within the shroud, is perforated so that gas may pass from the interior of the tube into the interior of the shroud 12. A removable cover 25 tightly closes the projecting left end of the tube 22 so as to prevent leakage of gas therefrom.

A gas exhaust conduit 26 is positioned in communication with the interior of the tube 22 so as to permit gas to be exhausted from the tube and thus from the shroud.

A conventional gas filter 27 is positioned in the conduit 26 and is utilized to filter and remove any dirt, dust or like materials entrained in the exhausted gas.

A generally cylindrical, rotatable chamber 28 is mounted within the interior of the shroud 12 on the flanged end 29 of a rotatable shaft 31 and is arranged so that the central longitudinal axis of the chamber 28, shaft 31 and the tube 22 are coaxial. The shaft 31 projects into the shroud through a conventionally sealed aperture 32 mounted in the rear wall 16 of the shroud. The dimensions of the interior of the shroud are such that when the chamber 28 is positioned within the shroud, as shown in FIG. 1, there is ample clearance between the chamber and the walls of the shroud whereby the chamber may be rotated within the shroud at relatively high speeds without danger of contact between the rotating chamber and the walls of the shroud.

Adjacent to the rear wall 16, the shaft 31 is journaled in conventional bearings 33 carried by a pedestal support 34 which is mounted on the floor 13. The other end 35- of the shaft 31 is journaled in a conventional bearing 36 which is carried by a second pedestal support 37 also mounted on the floor 13. A plurality of sheaves or pulleys 38 are mounted on the shaft 23 adjacent the bearing 36. The sheaves 38 are adapted to be driven by the V-belts 39.

A conventional two-speed electric motor 40 is mounted on a support 41 which in turn is positioned on the floor 13. The motor 41 is of the type which will permit the polarity of its windings to be reversed by changing the connections of the motor windings so that when the connections are reversed, the motor will act as a brake.

The output shaft 42 of the motor has a pair of sheaves or pulleys 43 mounted thereon. These sheaves 43 receive the V-belts 39 so that the motor 40 is connected with and thus selectively drives or brakes the shaft 31 and the chamber 2-8.

A conventional air or gas blower 44 is also driven by the motor 40. As shown in FIG. 1 the inlet 45 of the blower 44 communicates directly with the atmosphere, although, of course, the inlet 45 could be connected with another source of gas or'air. The outlet of the blower 44 is connected by a conduit 46 with the interior of the shroud 12. More particularly, the conduit 46 extends from the blower 44 to an inlet 47 formed in the bottom wall 17 of the shroud 12.

As shown schematically in FIG. 1, a conventional gas heating unit, shown schematically at 48, is positioned adjacent the inlet 47. The purpose of the unit 48 is to heat the gas being introduced into the shroud from the blower so that the high temperature gas may be used, during at least a portion of the cycle of operation of the machine 11, to heat the particles being shaped and treated within the chamber 28.

The chamber 28 includes generally circular front and back end walls 49 and 51 and a continuous, annular side wall 52. The side wall is formed so that its central portion 53 is spaced radially inwardly, relative to the end portions thereof, and so that the side wall is symmetrical about a plane passing through the center of the side wall 52 and perpendicular to the central longitudinal axis of the chamber.

An aperture 54 is formed in the front end wall 49, with the diameter of the aperture 54 being substantially equal to the diameter of the tube 22. The chamber 28 is positioned within the shroud 12 so that the center of the aperture 54 is aligned with the central longitudinal axis of the tube 22. The open, right end 23 of the tube 22 and the peripheral edge of the aperture 54 may be formed, as shown, so that a conventional running gas seal 55 is provided therebetween. This arrangement of the tube and aperture 54 permits gas to flow freely from the interior of the chamber and the interior of the tube. Moreover, as

noted above, gas may pass from the interior of the tube through the filter 24, and the perforations in the tube 22 and into the interior of the shroud 12.

A loading conduit 56 is mounted in the tube 22 and is used for introducing the soap or synthetic detergent particles 57 to be shaped and treated into the interior of the chamber 28. The conduit 56 is positioned Within the tube 22 so that one end 58 thereof extends through the cover 25. The other end 59 of the conduit 56 is supported adjacent to, but spaced from, the periphery of the aperture 54.

The end 58 of the conduit 56 is positioned higher, relative to the ground 13, than the other end 59 so that the particles may be gravity-fed into the interior of the chamber 28.

An unloading conduit 61 is also mounted in the tube 22 and is used to remove the beads, i.e., the particles which have been shaped and treated in the chamber, from the chamber. Like conduit 56, conduit 61 is positioned so that one end 62 thereof extends through the cover and the other end 63 thereof is supported adjacent to, but spaced from, the periphery of the aperture 54. The end 63 of conduit 61 is higher, relative to the ground 13, than the end 62 so that the beads will move through the conduit 61 from the end 63 to the end 62 by gravity.

A trough 64 has its open end 65 supported by the bracket '66 and extends across the chamber 28, with the longitudinal axis of the trough being generally parallel with, but spaced from, the central longitudinal axis of the chamber, The end 65 of the trough is positioned immediately above the other end 63 of the conduit 61, and the end 67 of the trough is positioned adjacent to, but not in contact with, the rear wall 51 of the chamber 28. The trough 64 is generally U shaped in cross-section, i.e., generally U shaped in a plane perpendicular to its central longitudinal axis.

A conventional electric motor 68 is also mounted on the bracket 66, and connected with the end 65 of the trough 64 so that the trough 64 may be rotated by the motor about the central longitudinal axis of the trough from a first position, such as shown in FIG. 4, where the open side of the trough faces the upper segment of the chamber 28 to a second position, one-hundred and eighty degrees from the first position, where the open side of the trough faces the lower segment of the chamber, such as shown in FIG. 6.

A conventional electrical vibrator unit, shown schematically at 69, is connected with the trough 64 and is utilized to vibrate the trough 64 so as to assure that the beads caught therein, as hereinafter described, are moved along the trough from the end 67 toward the end 65. As noted above, the trough 64 is positioned so that its end 65 is positioned above and adjacent to the end 63 of the conduit 61. When the beads caught in the trough are moved toward the open end 65, as a result of the operation of the unit 69, they fall into the conduit 61, and thus are removed from the machine 11. The vibrator unit 69 may be of the 6 type manufactured and sold by the Syntron Division of FMC Corporation, Homer City, Pa.

A conventional spray nozzle 71 is positioned within the chamber 28, adjacent the center thereof, and may be used to spray fluids onto the particles in the lower segment of the chamber. The nozzle 71 is connected with and supported by a pipe 72 which extends from the chamber 28 through the tube 22 and cover 25.. The pipe may be connected to one or more sources of pressurized fluid, not shown. A conventional pipe coupling 73 is used in the pipe 72 to facilitate removal of the cover 25. A conventional, electrically controlled valve 74 is positioned in the pipe 72 and controls flow through the pipe.

A plurality of relatively small diameter holes 75 are drilled in the front and rear walls 49 and 51 of the chamber 28 adjacent to, but spaced radially inwardly from, the side wall 52. The holes 75 are equi-spaced about a circle having as its center the central longitudinal axis of the chamber. The holes are arranged with respect to the side wall 52 so that when the gas under pressure is introduced into the chamber 28 through the holes, as hereinafter described, a generally annular fluidized bed or layer of particles and gas is formed in the chamber 28, during rotation of the chamber.

A unique fan-plenum chamber assembly 76 is utilized to force gas, under pressure, into the interior of the chamber 28 through the holes 75. This assembly 76, shown best in FIGS. 2 and 3, consists of a plurality of curved fan blades 77 and plenum chambers 78 which are mounted on the exterior faces 79 of both the front and rear walls 49 and 51. Since the assemblies 76 mounted on the walls 49 and 51 are identical, only the assembly 76 on the wall 51 will be described in detail.

As shown in FIGS. 2 and 3, the plenum chambers 78 are wider at their radial outer ends, i.e., the ends adjacent to the periphery of the wall 51, than at their radial inner ends, i.e., the ends adjacent to the center of the wall 51. The longitudinal center lines of the chambers 78 are disposed at an acute angle, e.g., 20-30, with respect to a radius of the wall 51, with the inner ends of each chamber 78 leading the outer end thereof in the direction of rotation of the chamber 28, this direction of rotation being indicated by the arrow 81 in FIG. 2.

All the fan blades and plenum chambers are structurally and functionally identical and, as best shown in FIG. 3, each chamber 78 includes a top panel 82 spaced from and parallel with the exterior face 79 of the end wall 51 of the chamber 28. The outer radial edge of the top panel 82 overlies and is congruent with the underlying periph eral arc of the end wall 51 so that the top panel overlies a number of the holes 75. While in FIG. 3, the top panel 82 is shown overlying or covering three holes 75, the specific number of holes covered by a top panel 82 is not critical so long as proper fluidization is obtained in chamber 28.

A pair of side panels 83 extend between the exterior face 79 and the side edges of the top panel 82. As shown in FIG. 2, the side panels 83 converge together at their radially inner ends, i.e., the inner ends of the side panels are spaced closer together than the outer ends thereof, so that each chamber 78 has a generally frusto-conical shape. An outer end panel 84 extends between the exterior face 79, the outer edge of the top panel 82 and between the radially outer ends of the side panels 83 so as to completely close the radially outer end of the chamber 78, except, of course, for the holes 75 enclosed within the chamber 78. An inner end panel 85 extends between the radially inner ends of the side panels 83 and the face 79 of wall 51. An opening 86 is defined in the top of the chamber 78 between the radial inner end 87 of the top panel 82, the inner end panel 85 and the side panels 83.

The curved fan blade 77 projects beyond the plane of the top panel 82, is integrally formed with the trailing side panel 82, relative to the direction of rotation of the chamber 28, and extends along the side of the opening 86. The axial height of the blades 77, relative to the chamber 78, is determined by the gas capacity or volume of flow desired.

The fan blades 77 are utilized during rotation of the chamber 28 to forcibly direct the gas in the shroud 12 into the plenum chambers 78 and hence, under pressure, through the holes 75 into the chamber 28. The design of the plenum chambers 78, including the angular disposition of the plenum chambers 78, relative to a radius of the end wall 51, assists in forcing gas through the plenum chambers 78 and into the chamber 28 during rotation of the chamber in a manner similar to that of a conventional centrifugal blower or fan.

The operation of the motor 68, the vibrator unit 64, the motor 40, the unit 48 and the valve 74 is controlled by a conventional timing mechanism '88. The timing mechanism 88 employs an electric motor which sequentially operates a plurality of switches in a preselected sequence.

Such timing mechanisms are old and well known in the art and for this reason, further description thereof has not been included herein.

A machine 89, partially shown in FIGS. 7 and 8, is structurally and functionally similar to machine 11 except that the machine 89 includes an alternate means for introducing fiuidizing gas into the rotating chamber 90. The detailed description of the machine 89 has been limited to the parts thereof which are different from the corresponding parts in machine 11 and the same reference numerals have been used to indicate common parts in machines 11 and 89.

Chamber 90 is structurally similar to chamber 28, except that its side wall 91 is straight, as distinguished from the curved side Wall 52. For this reason, a further detailed description of the chamber 90 is not included herein.

Chamber 90 utilizes a manifold 92 and a plurality of radial and transverse pipes 93 and 94, respectively, to accomplish the same function as is accomplished by the fan-plenum chamber assembly 76 used in connection with chamber 28. The manifold 92 is centrally mounted on the end wall 51 and interconnects the end 95 of the shaft 96 and the end wall 51 of the chamber 90. The shaft 96, supported and driven in amanner similar to shaft 31, is similar to shaft 31 except that the shaft 96 includes a central passage, not shown. The manifold 92 is connected with the outlet of a rotary compressor, shown schematically at 97, by means of a conduit 98 which, in turn, is in communication with the central passage in the shaft 96. The shaft 96 performs the dual function of supporting the chamber 90 for rotation as well as supplying gas to the manifold 92.

Each of the radial pipes 93 is connected at one end, through a metered orifice 101, with the manifold 92. As best shown in FIG. 8, the pipes 93 are equi-spaced around the circumference of the manifold 92, and extend radially outwardly, adjacent to the end wall 51, from the manifold so that the outer ends thereof project beyond the periphery of the chamber 90, i.e., just beyond the side wall 91. Each pipe 93 is connected at its radial outer end with an end of a transverse pipe 94 which extends axially, adjacent to the outer surface of and across the side wall 91. The other end of the transverse pipe 94 is closed.

Each of the transverse pipes 94 has a plurality of tubes 102 connected thereto which extend radially inwardly, relative to the central longitudinal axis of the chamber 90, through the side wall 91 of the chamber 90 into the interior of the chamber so that the open, inner ends of the tubes 102 project slightly beyond the inner surface of the side wall 91. As shown in FIGS. 7 and 8, the tubes 102 and the inner ends thereof are spaced closely together so that the pressurized gas emitted from the ends of the tubes 102 is capable of creating and maintaining a bed of fluidizing particles and gas in the chamber 90.

8 DESCRIPTION OF OPERATION As described above, the synthetic detergent or soap particles 57 which are to be shaped and/or treated in machine 11 are introduced into the rotating chamber 28 through the conduit 56. These particles may be the end product from a conventional spray tower utilized in the manufacture of irregularly shaped, conventional soap and detergent particles and may be conveyed directly from the bottom of the tower into the chamber 28 or from a hopper.

The rotational speed of the chamber 28 is selected so that during relatively high-speed rotation of the chamber, the particles will form and maintain a generally annular bed or layer adjacent to the side wall '52 of the chamber, as shown in FIG. 4. Moreover, because of the fan-plenum chamber assembly 76 mounted on the end walls 49 and 51 of the chamber, the gas in the interior of the shroud 12 is forced through the holes 75' formed in the end walls 49 and 5 1. The number and size of the fans 77 and plenum chambers 78 are correlated with the rotational speed of the chamber 28 so that the gas being forced into the rotating chamber through the holes 75 is sufficient to form a completely fluidized bed of particles and gas. In this annular fluidized bed, the particles are in continuous agitated motion as the gas passes into and through the bed so that the particles continually strike and come into contact with each other and with the walls of the chamber 28 whereby the particles are shaped into compact, generally spherical beads. After passing through the bed, gas is exhausted from the chamber 28 through the aperture 54. A portion of the exhausted gas is then removed from the machine through conduit 26 and the remainder of the gas is recirculated back into the interior of the shroud 12 through the filter 24. This recirculated gas, of course, is again introduced into the chamber 28.

To assist in the shaping of the particles, the gas introduced into the shroud 12 may be heated by the heating unit 48 to a temperature whereby the heated gas causes the particles to become somewhat plasticized. In addition, the fluidization and heating of the particles reduces the moisture content of the particles far below that of the original particles and, for example, below five percent by weight. Thus, the moisture content of the particles and resulting beads of this invention is significantly less than that of conventional soap or detergent particles.

If it is desired to treat or coat the particles in the chamber 28, a treating or coating fluid may be introduced in the rotating chamber and sprayed onto the particles through the nozzle 71. The timing mechanism 88 controls the flow through the valve 74, and thus through the nozzle 71, and therefore, if desired, the introduction of the fluid may be regulated with respect to the rotation of the chamber.

Periodically, the timing mechanism 88 causes the windings of the motor 40 to be reversed so that the motor abruptly brakes the chamber 28, thus causing the speed of the chamber 28 to be reduced from the relatively high speed at which the particles form and maintain a generally annular bed to an intermediate speed setting for the two-speed motor 40. This intermediate speed may just be five or ten percent less than the relatively high speed, but must be low enough so that the gravitational force acting on the particles overcomes the centrifugal force acting on the particles whereby the particles in the upper segment of the chamber fall away from the side wall 52 and are cast down upon the lower segment of the chamber and upon the particles in the bed in the lower segment of the chamber, as shown in FIG. 5. This causes additional compaction of the particles and hardens the outer surface of the particles. Moreover, during the time the speed of the chamber is below the relatively high speed, the particles are tumbled in the chamber and this also assists in shaping and hardening the particles. Almost immediately after the timing mechanism 88 has caused a reduction in the speed of the chamber 28, the timing mechanism causes the windings of the motor 40 to be switched back to their original position so that the motor again drives the chamber 28 at the relatively high speed.

A typical cycle operation for forming and maintaining the annular bed in the chamber 28, abruptly braking or reducing the rotational speed of the chamber to the intermediate speed and returning the speed of the chamber back to the relatively high speed, may take from to seconds. Approximately onehalf of this cycle may be utilized for forming and maintaining the particles in the annular bed, approximately one-quarter of the cycle may be utilized for reducing the speed of the chamber from the relatively high speed to the intermediate speed and the other one-quarter of the cycle may be utilized for tumbling the particles during the time the speed of the chamber is below the relatively high speed and for returning the rotational speed of the chamber from the intermediate speed to the relatively high speed or, of course, the periods of relatively high speed operation or intermediate speed operation may be made of much longer duration.

The operation of the machine 89 shown in FIG. 7 is identical to the foregoing description of the machine 11, except that the gas is introduced into the chamber 90 through the manifold 92 and a plurality of pipes 93 and 94. The gas may be heated, if desired, prior to its introduction into the manifold by a conventional heater, not shown, positioned in conduit 98. The operation of ma chine 89 does include the recirculation of gas.

After the particles 5-7 have been shaped and treated in the chamber a sufiicient length of time, i.e., for a sufficient number of cycles of operation, the resulting beads appear generally as shown in FIG. 9, with the reference numerals 103 indicating the portion of the head which was introduced into the chamber and the reference numeral 104 indicating a layer of coating material which was added to the portion 103 during the treatment of the particles in the chamber.

As noted above, the trough 64 is positioned, as shown in FIGS. 4 and 5, so that its open side is directed toward the lower segment of the chamber during the time the particles are being shaped and/ or treated in the chamber 28. When the desired number of cycles of operation have been completed, however, the timing mechanism 88 actuates the electric motor 68 and the motor rotates the trough one-hundred and eighty degrees from the position shown in FIGS. 4 and 5 to the position shown in FIG. 6 wherein the open side of the trough is directed toward the upper segment of the chamber. Thus, when the chamber 28 is next abruptly braked from the relatively high speed to the intermediate speed, a portion of the beads falling away from the upper segment of the chamber land in or are caught in the trough 64. When the trough 64 is in the position shown in FIG. 4, the timing mechanism 88 also causes the vibrator units 69 to operate so that the beads caught in the trough 64 are moved toward the left, as shown in FIG. 1, are deposited in the conduit 61 and are thereby removed from the machine. As the operation of the machine is repeated, the chamber 28 is completely emptied of beads.

The beads produced by the machines described herein have a density of greater than fifty pounds per cubic foot and a generally specific gravity for the bead of approximately nine-tenths, with a moisture content of below five percent by weight. These beads are designed for use in automatic washers which are equipped with mechanical or hydraulic dissolvers, and in which the clothes or fabrics to be cleaned are not introduced into the washer until after the beads have been thoroughly dissolved and diluted.

The composition or makeup of the beads produced by the machines of this invention may vary. For example, a bead produced in machines of this invention may have a nucleus of potash soap protected by a continuous, outer layer of soda soap. The soda soap layer, of course, would be introduced through the nozzle 71 while the nucleus of potash soap would be introduced into the chamber through the conduit 56. The advantage of using a head of this type is that the active ingredients of soda soap cost approximately one-half the cost of the active ingredients of synthetic detergents. The out-er layer of soda soap is to prevent the caking or absorbtion of moisture by the more active potash soap nucleus.

Another type of head which could be produced is a bead having a mild caustic detergent outer layer with a nucleus of a strong caustic detergent so that when the bead is dissolved to a concentration of three-tenths percent in soft water, i.e., water having below 50 parts per million of hardeness components, the solution of clothes and water would have a pH of -10. A similar type of head could be used in hard water, i.e., water having hardness components of between 50 and 200 parts per million, so that when the head is dissolved, to a concentration of five-tenths percent, the solution of clothes and water would have a pH of 9.512.0. The advantage of using the milder outer caustic layer is that it would facilitate the handling of the beads and permit, for the first time, a strong caustic solution, such as now used in the commercial laundries, to be safely used in the home.

Likewise, the beads produced in the machines of this invention could also have a nucleus of a bluing material, a fluorescent bluing dye, a clothes bleaching chemical or a rinse promoting chemical with the outer layer being a detergent product. Still another example of such beads would be a bead having an outer layer of water softening chemicals, such as metasilicate, and a nucleus of potash soap.

The variations and different combinations of nucleus and outer layer materials which may be utilized for the soap and detergent beads of the present invention, of course, is not limited to the examples given above; and it should be understood that the machines of this invention provide an economical and efiicient way of producing laundry products in a dense bead form in which two or more products can be combined so that each head contains the same chemicals and same proportion of chemicals as all other beads, within, of course, normal manufacturing tolerances.

Thus, it should be apparent from the foregoing that the invention described herein provides a unique and novel machine and method for shaping and treating laundry products which will permit those products to be economically attractively sold both to the home and commercial laundry market. In addition, the machines and method described herein permits the production of detergent products which will, for the first time, permit the home laundry market to utilize harsher chemicals and a wider variety of detergent products than could heretofore be safely commercially sold.

Also, it should be obvious to those skilled in the art that the specific machines described herein could be modified without departing from the principles of the invention. For example, the trough 64 could also be arranged so that it could be completely withdrawn from the chamber 28 when not in use, rather than be positioned such as shown in FIGS. 4 and 5.

Also, other means could be used to direct gas or air under pressure into the rotating chamber; and in connection with the shaping and treating of certain particles it may not be necessary to periodically, abruptly reduce the rotational speed of the chamber. In some instances, and particularly with a machine similar to that shown in FIGS. 7 and 8, the tumbling of the particles in the chamber may be accomplished by abruptly varying the fiow and/ or pressure of the gas or air introduced into the chamber. In addition, and as noted above, the size, number and angle of the plenum chambers and fan blades used in the machine 11 may be varied, depending on the particles to be shaped and/or treated and, of course, the cycle of operations can be changed.

Therefore, the preferred embodiments of the invention described herein are to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are thus intended to be embraced therein.

I claim as my invention:

1. An improved machine for shaping and treating particles of soap, detergent and the like comprising: a rotatable chamber having end walls and a side wall and being adapted to receive the particles; means for rotating the chamber about its central axis at a relatively high speed whereby the particles form and maintain a generally annular bed about said central axis and adjacent the side wall of the rotating chamber; means for continuously introducing gas under pressure into said annular bed so that the particles are fluidized in said annular bed; and means for causing the fluidized particles in said annular bed to be impinged intermittently against the walls of the rotating chamber and against the other fluidized particles in said annular bed so that the fluidized particles are intermittently tumbled in, and against the walls, of the rotating chamber.

2. The improved machine described in claim 1 which includes means for introducing particle-treating fluid into the rotating chamber so that said fluid contacts the fluidized particles in said annular bed.

3. The improved machine described in claim 1 wherein the means for causing the fluidized particles in said annular bed to impinge intermittently against the walls of the rotating chamber and the other fluidized particles in said annular bed includes means for periodically, abruptly changing the rotational speed of the rotating chamber.

4. The improved machine described in claim 3 wherein the means for changing the speed of the rotating chamber periodically, abruptly reduces the speed of the rotating chamber from said high speed to an intermediate speed.

5. The improved machine described in claim 4 wherein the central axis of the chamber is substantially horizontal; and wherein said intermediate speed is below the rotational speed needed to maintain said annular bed of particles so that when the speed of the chamber is periodically, abruptly reduced, a large portion of the fluidized particles fall away from adjacent the side Wall of the rotating chamber and are cast down on the lower segment of the rotating chamber.

6. The improved machine described in claim 5 which includes means for introducing particles intothe interior of the rotating chamber during rotation of the rotating chamber and means for removing particles from the rotating chamber during rotation of the rotating chamber.

7. The improved machine described in claim 5 wherein the means for changing the rotational speed of the rotating chamber quickly returns the rotating chamber to said relatively high speed after a reduction of rotational speed whereby said annular bed of fluidized particles and gas is again formed.

8. The improved machine described in claim 6 which includes means for introducing particle-treating fluid into the rotating chamber so that said fluid contacts the fluidized particles in said annular bed.

9. The improved machine described in claim 1 wherein the central axis of the chamber is horizontal.

10. The improved machine described in claim 1 wherein the means for causing the fluidized particles in said annular bed to impinge intermittently against the walls of the rotating chamber includes means for periodically introducing into the chamber a volume of gas under pressure in excess of that needed to fluidize the particles in the rotating chamber whereby the excess gas causes the fluidized particles to be intermittently impinged against the walls of the rotating chamber.

11. The improved machine described in claim 1 which includes means for introducing particles into the interior 12 of the rotating chamber during rotation of the chamber and means for removing particles from the rotating chamber during rotation of the chamber.

12. The improved machine described in claim 1 wherein the means for introducing gas under pressure into said annular bed includes a plurality of holes formed in the rotating chamber, said holes permitting communication between the exterior of the rotating chamber and said annular bed in the rotating chamber; and means positioned without the rotating chamber for causing gas under pressure to flow through said holes into the rotating chamber.

13. The improved machine described in claim 12 wherein the means for causing gas to flow into the rotating chamber includes a plurality of fan blades mounted on the exterior face of at least one of the end walls of said rotating chamber whereby the fan blades cause gas surrounding said rotating chamber to be forced into the rotating chamber through said holes.

14. The improved machine described in claim 13 wherein said holes are formed in the end walls of the rotating chamber, adjacent to, but spaced radially inwardly from the side wall of the rotating chamber; wherein the fan blades are mounted on each of the end walls at points equi-spaced from each other and at points spaced radially inward from the side wall, with the longitudinal axis of each of the fan blades being disposed at an acute angle with respect to a radius of the rotating chamber and with the fan blades being spaced radially closer to said central axis of the rotating chamber than said holes; and wherein a plurality of plenum chambers are formed on the exterior face of the end walls of the rotating chamber and are arranged so that a plenum chamber extends from each of the fan blades to at least one of said holes whereby the plenum chamber serves to direct gas from the fan blade radially outwardly to and through said holes.

15. The improved machine described in claim 14 wherein the fan blades are positioned ahead, relative to the direction of the rotation of the rotating chamber, of the respective said holes with which the fan blades are connected by a plenum chamber so that the plenum chamber assists in the movement of gas radially through the plenum chamber and through said holes.

16. The improved machine described in claim 14 wherein a shroud is positioned so as to surround the rotating chamber; wherein gas is introduced into the interior of the shroud; and wherein gas heating means is used to heat the gas introduced into the shroud.

17. The improved machine described in claim 16 wherein the gas fluidizing said annular bed of particles flows from said annular bed into the interior of the shroud through an aperture formed in at least one of the end walls of the rotating chamber, adjacent said central axis of the rotating chamber, so that at least a portion of the gas may be recirculated and reintroduced into the annular bed; wherein means are positioned adjacent the rotating chamber to filter the gas being recirculated; and wherein means are used to control selectively the operation of the gas heating means.

18. The improved machine described in claim 12 wherem the means for introducing gas under pressure into said annular bed includes: a manifold positioned adjacent said central axis of the rotating chamber; a gas rotary compressor having its outlet connected with the manifold; a plurality of generally L-shaped conduits, each conduit having one of its ends blocked and the other of its ends connected with the manifold, having a first section thereof extending from the manifold to the periphery of the rotating chamber and having a second section thereof extending adjacent to the side wall of the rotating chamber, substantially parallel to said central axis of the rotating chamber; metering orifices associated with each of the conduits; a plurality of short tubes connected with the second sections of the conduits and extending radially inwardly therefrom through the side wall of the rotating chamber so that the radially inner open ends of the tubes are spaced adjacent to, but radially inwardly from, the inner surface of the side wall of the rotating chamber whereby gas under pressure is emitted from the inner open ends of the tubes into said annular bed.

19. The improved machine described in claim 18 wherein the first sections of the conduits extend radially along the exterior face of one of the end walls of the rotating chamber.

20. The improved machine described in claim 1 wherein a stationary shroud is positioned so as to surround the rotating chamber; wherein gas is introduced into the interior of the shroud; and wherein gas heating means is used to heat the gas introduced into the shroud.

21. The improved machine described in claim 20 wherein the gas fiuidizing said annular bed of particles flows from said annular bed into the interior of the shroud through an aperture formed in at least one of the end walls of the rotating chamber adjacent said central axis of the chamber so that at least a portion of the gas may be recirculated and reintroduced into said annular bed; and wherein filter means are positioned adjacent the totating chamber to filter the gas being recirculated.

22. The improved machine described in claim 2 wherein the means for introducing fluid into the rotating chamber includes a relatively stationary nozzle positioned within the rotating chamber and a conduit connecting the nozzle with a source of fluid under pressure, the central longitudinal axis of the conduit being, at least in part, parallel with said central axis of the rotating chamber.

23. The improved machine described in claim 5 wherein the side wall of the rotating chamber is curved and is symmetrical about a plane extending through the center of the side wall and perpendicular to said central axis of the rotating chamber.

24. The improved machine described in claim 23 wherein the central portion of the side wall of the rotating chamber is spaced radially inwardly, relative to the end portions of the side wall.

25. The improved machine described in claim 6 wherein the means for removing the particles from the rotating chamber includes a trough having a generally U-shaped cross section, in a plane perpendicular to the central longitudinal axis of the trough; with the trough being positioned in the rotating chamber adjacent to said central axis of the chamber.

26. The improved machine described in claim 25 wherein said central longitudinal axis of the trough is substantially parallel to said central longitudinal axis of the rotating chamber.

27. The improved machine described in claim 26 wherein the trough is mounted within the rotating chamber so that it may be positioned selectively either in a first position in which the trough faces the upper segment of the rotating chamber whereby when the rotational speed of the chamber is periodically abruptly reduced, at least a portion of the particles falling away from the side wall of the rotating chamber are caught in the trough, or in a second position in which the trough is rotated approximately 180 from said first position.

28. The improved machine described in claim 26 wherein one end of the trough extends through an aperture formed in one of the end walls of the rotating chamber; and wherein means are included for vibrating the trough whereby the vibration of the trough assists in moving the particles caught in the trough along the trough toward the one end thereof.

29. The improved machine described in claim 15 which includes means for introducing particles into the interior of the rotating chamber during rotation of the chamber; wherein said central axis of the rotating chamber is sub stantially horizontal; wherein the means for causing the fluidized particles in said annular bed to impinge intermittently against the walls of the rotating chamber in cludes means for periodically, abruptly reducing the speed of the rotating chamber from a high speed to an intermediate speed, said intermediate speed being below the rotational speed needed to maintain said annular bed of fluidized particles so that when the speed of the chamber is periodically, abruptly reduced at large portion of the fluidized particles fall away from adjacent the side wall of the rotating chamber and are cast down on the lower segment of the rotating chamber; wherein the means for changing the rotational speed of the rotating chamber quickly returns the rotating chamber to said relatively high speed after reduction of rotational speed whereby said annular bed of fluidized particles and gas is again formed; wherein a trough is used for removing the particles from the rotating chamber, the trough having a generally U- shaped cross section, in a plane perpendicular to the central longitudinal axis of the trough and being mounted within the rotating chamber so that it may be positioned selectively either in a first position in which the trough faces the upper segment of the rotating chamber whereby when the rotational speed of the chamber is periodically, abruptly reduced, at least a portion of the fluidized particles falling away from the side wall of the rotating chamber are caught in the trough, or in a second position in which the trough is rotated approximately from said first position; wherein a shroud is positioned so as to surround the rotating chamber; wherein gas is introduced under pressure into the interior of the shroud; wherein a gas heating means is used to heat the gas introduced into the shroud; wherein means are used to control selectively the operation of the gas heating means; wherein the gas fluidizing said annular bed of particles flows from said annular bed into the interior of the shroud through an aperture formed in at least one of the end walls of the rotating chamber adjacent said central axis of the chamber so that at least a portion of the gas may be recirculated and reintroduced into said annular bed; wherein filter means are positioned adjacent the rotating chamber to filter the gas being recirculated; wherein a relatively stationary nozzle means is used to introduce fluid into the rotating chamber including a nozzle positioned within the rotating chamber and a conduit connecting the nozzle with a source of fluid under pressure, the central longitudinal axis of the conduit being, at least in part, coaxial with said central axis of the rotating chamber; and wherein the side wall of the rotating chamber is curved and is symmetrical about a plane extending through the center of the side wall and perpendicular to said central axis of the rotating chamber, with the central portion of the side wall of the rotating chamber being spaced radially inwardly, relative to the end portions of the side wall.

References Cited UNITED STATES PATENTS 2,165,287 7/1939 McBride 24154X JAMES M. MEISTER, Primary Examiner US. Cl. X.R. l8-2.6

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 3,588,950 D d June 29, 1971 Inventor(s) D. E. Marshall It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

In the drawings, Sheet 1, Fig. 1, lines 2-2, directed toward chamber 28, should be inserted between the front wall 14 of the shroud l2 and the front wall 49 of the chamber 28; the reference number 11 should be generally applied to the machine; the reference number 65 should be applied to the end of the trough 64 adjacent the unloading conduit 61; the reference number 68 should be applied to the schematic box adjacent bracket 66. In the drawings, Sheet 2, Fig. 2, the reference number 81 should be applied to the arrow indicating the direction of rotation of the chamber 28. In the drawings, Sheet 3, Fig. 7, the reference number 91 should be applied to the side wall connecting front end wall 49 and back end wall 51; the reference number 93 should be instead applied to the pipe running vertically down the back end wall 51. Column 7, line 49, reference number 99 should be inserted to follow "passage".

Signed and sealed this 8th day of February 1972.

(SEAL) Attest:

EDWARD M.FLETGHER, .73, ROBERT GOTTSCHALK Attesting Officer Commissioner of Patents FORM PC3-1050 (10- USCOMM'DC scan-Pee LLSi GOVERNMENT PRINTING OFFICE I969 O36G-33l 

